HEMT GaN DEVICE WITH A NON-UNIFORM LATERAL TWO DIMENSIONAL ELECTRON GAS PROFILE AND METHOD OF MANUFACTURING THE SAME

ABSTRACT

A high electron mobility field effect transistor (HEMT) having a substrate, a channel layer on the substrate and a barrier layer on the channel layer includes a stress inducing layer on the barrier layer, the stress inducing layer varying a piezo-electric effect in the barrier layer in a drift region between a gate and a drain, wherein a two dimensional electron gas (2DEG) has a non-uniform lateral distribution in the drift region between the gate and the drain, wherein the stress inducing layer comprises a material having a height that decreases linearly and monotonically in the drift region in the direction from the gate towards the drain, and wherein the 2DEG decreases in density in the drift region between the gate and the drain.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of U.S. patent application Ser. No. 15/005,744 filed on Jan. 25, 2016, which is a divisional of U.S. patent application Ser. No. 13/478,609 filed on May 23, 2012, and this application claims the benefit of U.S. patent application Ser. No. 15/005,744 filed on Jan. 25, 2016, and U.S. patent application Ser. No. 13/478,609 filed on May 23, 2012, which are incorporated herein by reference as though set forth in full. This application is related to U.S. patent application Ser. No. 13/479,018 filed May 23, 2012 and to U.S. patent application Ser. No. 13/478,402 filed May 22, 2012.

STATEMENT REGARDING FEDERAL FUNDING

NONE.

TECHNICAL FIELD

This disclosure relates to type III-nitride high electron mobility transistor (HEMT) devices and in particular to two dimensional electron gas (2DEG) in the drift region.

BACKGROUND

A high electron mobility transistor (HEMT) is a field effect transistor incorporating a junction between two materials with different band gaps (i.e., a heterojunction). Gallium nitride (GaN) HEMTs have attracted attention due to their high-power performance. In type III-nitride HEMT devices used in power applications there is a conflicting design trade-off between the on-state resistance and breakdown voltage (BV). Since the relation between the BV and on resistance is at least quadratic, improvement in the BV for a given drift region length results in a significant improvement in the FOM of the device, defined as BV²/Ron.

In the prior art type III-nitride HEMT devices have a uniform 2DEG density which results in a peak electric field under or near the gate region. The electric field distribution tends to be closer to a triangular shape than to the desired trapezoidal shape which reduces the breakdown voltage per unit drift region length of the device. The use of field plate and multistep field plates are some of the techniques that are used to improve the electric field distribution. However, field plates typically result in multiple peaks and suffer from less than an ideal flat field distribution, and may exhibit a saw tooth profile. Field plates also add to the gate to drain capacitance. In addition, process complexity and cost typically increase with the number of field plate steps.

U.S. Pat. No. 7,038,253 to Furukawa describes a GaN based device on silicon (Si) technology which uses a uniform 2DEG profile in the drift region. Because of the absence of any field shaping technique in the Furukawa device, the breakdown voltage and dynamic on resistance from drain to source is limited by a localized increase in the electric field under the gate region thus requiring over design of the device which degrades the figure of merit (FOM) that such a device can achieve.

In “High Breakdown Voltage AlGaN/GaN HEMTs Achieved by Multiple Field Plates” by H. Xing et. Al, a field shaping technique that uses multiple field plates is described to improve the electric field distribution. However, multiple field plates do not achieve a uniform electric field, may have a saw tooth type distribution, and introduce gate to drain capacitance. Implementing such a device structure also increases device complexity and cost.

What is needed is a significant improvement in the FOM in HEMT devices, and in particular an improvement in the breakdown voltage for a given drift region length, so that the FOM of the device, defined as BV²/Ron, improves. The embodiments of the present disclosure answer these and other needs.

SUMMARY

In a first embodiment disclosed herein, a high electron mobility field effect transistor (HEMT) having a substrate, a channel layer on the substrate and a barrier layer on the channel layer comprises a stress inducing layer on the barrier layer, the stress inducing layer varying a piezo-electric effect in the barrier layer in a drift region between a gate and a drain, wherein a two dimensional electron gas (2DEG) has a non-uniform lateral distribution in the drift region between the gate and the drain, wherein the stress inducing layer comprises a material having a height that decreases linearly and monotonically in the drift region in the direction from the gate towards the drain, and wherein the 2DEG decreases in density in the drift region between the gate and the drain.

In another embodiment disclosed herein, a method of fabricating a high electron mobility field effect transistor (HEMT) comprises forming a channel layer on a substrate, forming a barrier layer on the channel layer, and forming a stress inducing layer on the barrier layer, the stress inducing layer varying the piezo-electric effect in the barrier layer in a drift region between a gate and a drain, wherein a two dimensional electron gas (2DEG) has a non-uniform lateral distribution in the drift region between the gate and the drain.

These and other features and advantages will become further apparent from the detailed description and accompanying figures that follow. In the figures and description, numerals indicate the various features, like numerals referring to like features throughout both the drawings and the description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a deposited layer on top of the carrier supplying layer with varying size openings to induce a stress and modulate the density of a two dimensional electron gas (2DEG) in a HEMT device in accordance with the present disclosure;

FIG. 2 shows a deposited layer on top of the carrier supplying layer with a varying height profile to induce a stress and modulate the density of a two dimensional electron gas (2DEG) in a HEMT device in accordance with the present disclosure;

FIGS. 3A and 3B are flow diagrams for methods of fabricating a HEMT device in accordance with the present disclosure;

FIG. 4 shows another embodiment of a stress inducing layer with a varying height profile to induce a stress and modulate the density of a two dimensional electron gas (2DEG) in a HEMT device in accordance with the present disclosure; and

FIG. 5 shows a deposited layer on top of the carrier supplying layer with openings increasing in size from the gate to the drain in accordance with the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth to clearly describe various specific embodiments disclosed herein. One skilled in the art, however, will understand that the presently claimed invention may be practiced without all of the specific details discussed below. In other instances, well known features have not been described so as not to obscure the invention.

Referring now to FIG. 1, a field effect transistor (FET) device structure 10 is shown. The FET device structure 10 is composed of a stack of III-V layers, such as GaN layer 14 and AlGaN layer 16, grown on a substrate 12 that can be any of the suitable substrates that are commonly used to grow type III-Nitride materials. Suitable substrates include but are not limited to silicon (Si), Sapphire, silicon carbide (SiC), and bulk single crystal gallium nitride (GaN).

The stack of III-V layers may include a buffer layer of GaN or aluminum gallium nitride (AlGaN) grown on the substrate 12. Then a type III layer, such as GaN layer 14, for the channel and carrier travelling layer, is grown on the buffer layer. Then a type V layer, such as AlGaN layer 16, for the barrier layer and the carrier supplying layer, is grown on top of the GaN layer 14. An AlN spacer layer may be between the GaN layer 14 and the AlGaN layer 16 to improve device electrical performance.

As shown in FIG. 1, on top of the barrier layer layer 16 a stress inducing layer 46 is grown to induce a stress and modulate the charge in the 2DEG 42, as shown in FIG. 1. In one embodiment the stress inducing layer 46 is etched with openings 48 in specific areas, as shown in FIG. 1, using a mask. The stress inducing layer 46 modulates the stress in the stress inducing layer 46. The stress varies the piezoelectric effect in the barrier layer 16 and hence the 2DEG 42 in a drift region between the gate 22 and the drain 20.

The lateral control of the stress in the stress inducing layer 46 over the drift region may be achieved by etching different size openings 48 in the stress inducing layer 46 that either monotonically increase or monotonically decrease in size from the gate 22 to the drain 20 depending on the polarity of the stress the deposited layer is exerting on the barrier or charge supplying layer, as shown in FIG. 5 and FIG. 1, respectively. The number of opening is greater than two, as shown in FIG. 1 and FIG. 5.

If it is desired to increase the piezoelectric effect in the drift region from gate 22 to drain 20, the size of the openings 48 are larger near the gate 22 and decrease in size towards the drain 20, as shown in FIG. 1.

If it is desired to reduce the piezoelectric effect in the drift region from the gate 22 to the drain 20, the size of the openings 48 are made smaller near the gate 22 and increase in size towards the drain 20.

Since the density of charge in the 2DEG region is determined locally by the magnitude of the piezoelectric effect, a non-uniform 2DEG 42 distribution may be achieved by varying the magnitude of piezoelectric effect over the drift region as a function of distance from the gate 22 towards the drain 20 along the drift region. In the embodiment shown in FIG. 1 the piezoelectric effect in the drift region increases from the gate 22 towards the drain 20, and the size of the openings 48 are larger near the gate 22 and decrease in size towards the drain 20. Such an embodiment results in the 2DEG 42 varying in density such that the 2DEG increases in density in the drift region from the gate 22 towards the drain 20.

As described above, if it is desired to reduce the piezoelectric effect in the drift region from gate 22 to drain 20, the size of the openings 48 may be made smaller near the gate 22 and increased in size towards the drain 20.

In another embodiment, shown in FIG. 2, a stress inducing layer 50 is grown on top of the AlGaN layer 16. The non-uniform lateral 2DEG 44 is achieved in this embodiment by using Gray scale photolithography to form a stress inducing layer 50 having a lateral profile that has a height that varies.

Gray scale photolithography uses a gray scale mask to form a stress inducing layer 50 that has a lateral profile and has a height that increases or decreases in the drift region 52 of stress inducing layer 50 between the gate 22 and the drain 20, depending on the polarity of the stress to be induced.

In the embodiment shown in FIG. 2, the height of the stress inducing layer 50 increases in the drift region 52 of the stress inducing layer 50 starting at the gate 22 and continuing to the drain 20. Further, as shown in FIG. 2 the height of the stress inducing layer 50 may increase linearly and monotonically in the drift region 52 of the stress inducing layer 50 starting at the gate 22 and continuing to the drain 20. The stress inducing layer 50 varies the magnitude of piezoelectric effect over the drift region as a function of distance from the gate 22 towards the drain 20 along the drift region. In the embodiment shown in FIG. 2, the stress and the piezoelectric effect in the drift region increases from the gate 22 towards the drain 20. Such an embodiment results in the 2DEG 42 varying in density such that the 2DEG 44 increases in density in the drift region from the gate 22 towards the drain 20. In the embodiment shown in FIG. 4, the height of the stress inducing layer 50 decreases in the drift region 52 of the stress inducting layer 50 starting at the gate 22 and continuing to the drain 20. Further, as shown in FIG. 4 the height of the stress inducing layer 50 may decrease linearly and monotonically in the drift region 52 of the stress inducing layer 50 between the gate 22 and the drain 20. The stress inducing layer 50 varies the magnitude of piezoelectric effect over the drift region as a function of distance from the gate 22 towards the drain 20 along the drift region. In the embodiment shown in FIG. 4, the stress and the piezoelectric effect in the drift region decreases from the gate 22 towards the drain 20. Such an embodiment results in the 2DEG 42 varying in density such that the 2DEG 44 decreases in density in the drift region from the gate 22 towards the drain 20.

As described above, if it is desired to reduce the piezoelectric effect in the drift region from the gate 22 to the drain 20, the height of the stress inducing layer 50 decreases in the drift region in the direction from the gate 22 towards the drain 20.

The source contact 18 and the drain contact 20 are formed by metal evaporation or metal sputtering to contact the barrier layer 16 after opening a contact window in the stress inducing layer 46, in the embodiment of FIG. 1, or stress inducing layer 50, in the embodiment of FIG. 2.

A passivation layer 24 may be grown on top of the stress inducing layer 46 or the stress inducing layer 50.

A gate region is then formed by etching a trench through the passivation layer 24 and the stress inducing layer 46 or 50 in a gate area between the source 18 and drain 20 and into the AlGaN layer 16. In another embodiment the etched trench may extend through the AlGaN layer 16 and partially into the GaN layer 14 to an appropriate depth. A gate dielectric 26 is then deposited over the area between the source 18 and gate 22 and the gate 22 and the drain 20, and also deposited to line the etched trench that extends into the AlGaN layer 16. If the etched trench extends into the GaN layer 14, then the gate dielectric 26 also lines the etched trench that extends into the GaN layer 14.

After deposition of the gate dielectric 26, gate metal 22 is formed by evaporation or sputtering and fills the etched trench.

Various alternating passivation and metallization layers may be formed as a part of back-end processing to improve the parasitic resistance of the device and provide connection to device pads and/or a package.

Use of the stress inducing layer 46 or 50 to vary the piezo-electric effect in the barrier or charge supplying layer 16, and hence the 2DEG density in the drift region between the gate 22 and the drain 20, may provide a significant improvement of the figure of merit (FOM) in type III Nitride HEMT devices by achieving a flat electric field distribution in the drift region between the gate 22 and the drain 20. The 2DEG 42 is varied in the drift region to form a non-uniform lateral 2DEG distribution 44, as shown in FIGS. 1 and 2. A flat electric field distribution results from the non-uniform lateral 2DEG distribution 44 along the drift region which provides the improvement in the figure of merit (FOM), defined as BV²/Ron.

FIGS. 3A and 3B are flow diagrams for methods of fabricating a HEMT device in accordance with the present disclosure.

In step 100 a channel layer is formed on a substrate. Then in step 102 a barrier layer is formed on the channel layer. Next in step 104 a stress inducing layer is formed on the barrier layer, the stress inducing layer varying the piezo-electric effect in the barrier layer in a drift region between a gate and a drain, wherein a two dimensional electron gas (2deg) has a non-uniform lateral distribution in the drift region between the gate and the drain.

In step 106 forming the stress inducing layer on the barrier layer includes forming a material having a plurality of varying size openings between the gate and the drain, the plurality of varying size openings decrease or increase in size from the gate towards the drain.

In step 108 forming the stress inducing layer on the barrier layer includes forming a material having a height that increases or decreases from the gate towards the drain using gray scale photolithography.

In step 110 a passivation layer is formed over the barrier layer. In step 112 a gate is formed comprising the steps of forming a trench extending through the passivation layer and into the barrier layer, depositing a gate dielectric layer in the trench, and forming gate metal on the gate dielectric. In step 114 the forming a trench extending through the passivation layer and into the barrier layer further includes forming the trench to extend into the channel layer.

In step 116 an opening is formed in the stress inducing layer under the drain for providing contact of the drain to the barrier layer. And finally, in step 118 an opening is formed in the stress inducing layer under a source for providing contact of the source to the barrier layer

Having now described the invention in accordance with the requirements of the patent statutes, those skilled in this art will understand how to make changes and modifications to the present invention to meet their specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention as disclosed herein.

The foregoing Detailed Description of exemplary and preferred embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form(s) described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. Applicant has made this disclosure with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable. Reference to a claim element in the singular is not intended to mean “one and only one” unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the Claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for . . . ” and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase “comprising the step(s) of . . . .” 

What is claimed is:
 1. A high electron mobility field effect transistor (HEMT) having a substrate, a channel layer on the substrate and a barrier layer on the channel layer, the HEMT comprising: a stress inducing layer on the barrier layer, the stress inducing layer varying a piezo-electric effect in the barrier layer in a drift region between a gate and a drain; wherein a two dimensional electron gas (2DEG) has a non-uniform lateral distribution in the drift region between the gate and the drain; wherein the stress inducing layer comprises a material having a height that decreases linearly and monotonically in the drift region in the direction from the gate towards the drain; and wherein the 2DEG decreases in density in the drift region between the gate and the drain.
 2. The HEMT of claim 1 further comprising: an opening in the stress inducing layer under the drain for providing contact of the drain to the barrier layer; and an opening in the stress inducing layer under a source for providing contact of the source to the barrier layer.
 3. The HEMT of claim 1 further comprising: a passivation layer over the stress inducing layer.
 4. The HEMT of claim 1 wherein: the substrate comprises silicon (Si), sapphire, silicon carbide (SiC), OR bulk single crystal gallium nitride (GaN); the channel layer comprises a GaN layer; and the barrier layer comprises a AlGaN layer.
 5. The HEMT of claim 3 further comprising: a trench extending through the passivation layer and into the barrier layer; and a gate dielectric layer in the trench; and gate metal on the gate dielectric.
 6. The HEMT of claim 5 wherein the trench extends into the channel layer.
 7. A method of fabricating a high electron mobility field effect transistor (HEMT), the method comprising: forming a channel layer on a substrate; forming a barrier layer on the channel layer; and forming a stress inducing layer on the barrier layer, the stress inducing layer varying the piezo-electric effect in the barrier layer in a drift region between a gate and a drain; wherein a two dimensional electron gas (2DEG) has a non-uniform lateral distribution in the drift region between the gate and the drain.
 8. The method of claim 7 wherein forming the stress inducing layer on the barrier layer comprises forming a material having a plurality of varying size openings between the gate and the drain.
 9. The method of claim 8 wherein the plurality of varying size openings decrease in size from the gate towards the drain.
 10. The method of claim 8 wherein the plurality of varying size openings increase in size from the gate towards the drain.
 11. The method of claim 7 wherein forming the stress inducing layer on the barrier layer comprises forming a material having a height that increases linearly and monotonically from the gate towards the drain using gray scale photolithography.
 12. The method of claim 7 wherein forming the stress inducing layer on the barrier layer comprises forming a material having a height that decreases linearly and monotonically from the gate towards the drain using gray scale photolithography.
 13. The method of claim 7 wherein: the substrate comprises silicon (Si), sapphire, silicon carbide (SiC), OR bulk single crystal gallium nitride (GaN); the channel layer comprises a GaN layer; and the barrier layer comprises a AlGaN layer.
 14. The method of claim 7 further comprising: forming a passivation layer over the barrier layer; and forming a gate comprising the steps of: forming a trench extending through the passivation layer and into the barrier layer; and depositing a gate dielectric layer in the trench; and forming gate metal on the gate dielectric.
 15. The method of claim 14 wherein forming a trench extending through the passivation layer and into the barrier layer further comprises: forming the trench to extend into the channel layer.
 16. The method of claim 7 further comprising: forming an opening in the stress inducing layer under the drain for providing contact of the drain to the barrier layer; and forming an opening in the stress inducing layer under a source for providing contact of the source to the barrier layer. 